Packaging for disposable soft contact lenses

ABSTRACT

The present disclosure provides a contact lens package containing a contact lens in a compressed state. In one exemplary embodiment, the overall internal depth of the package is less than the natural sagittal depth of the contact lens. Different single-use contact lens package shapes and configurations may be used. In some embodiments, a spring disc is included in the packages to help present the contact lens to the user when the package is opened. The contact lens packages may be adhered or clipped to a card or other carrier sheet, and may be housed in a number of different secondary packages.

RELATED APPLICATIONS

The present application is a Divisional of U.S. application Ser. No.15/444,102, filed Feb. 27, 2017, now U.S. Pat. No. 10,194,724, which isa Continuation of U.S. application Ser. No. 14/596,791, filed Jan. 14,2015, now U.S. Pat. No. 9,615,639, which is a Divisional of U.S.application Ser. No. 12/892,890, filed Sep. 28, 2010, now U.S. Pat. No.8,955,672, which is a Continuation of U.S. application Ser. No.11/404,200, filed Apr. 13, 2006, now U.S. Pat. No. 7,828,137, which is aDivision of U.S. application Ser. No. 10/789,961, filed Feb. 17, 2004,now U.S. Pat. No. 7,086,526, which is a Continuation-In-Part of U.S.application Ser. No. 10/781,321, now abandoned, which is aContinuation-In-Part of International Patent Application No.PCT/AUO2/01105, filed Aug. 7, 2002, designating the United States, allof which are hereby incorporated by reference in their entireties.

BACKGROUND

The present systems and methods relates-to contact lens packaging andmore particularly, to an improved economic form of package for a contactlens which satisfies lens packaging criteria, including sterility andenvironmentally sensitive disposability.

PRIOR ART

Soft disposable contact lenses are commonly contained in disposablepackages. As packaging adds to the overall cost of the lens, it shouldbe made as economically as possible but without compromise to therequisite packaging criteria. The traditional blister pack packaging(shown in FIGS. 1-3) for disposable lenses (both bi-weekly and daily)consists of a polypropylene receptacle for the lens (herein afterreferred to as a “boat”), topped by a multi-layer film consisting ofpolyethylene, aluminum, a bonding agent and polypropylene. The boat isusually an injection molded plastic which has high stiffness but iscapable of limited elastic deflection and includes a preformed recess.The boat is filled with a suitable storage solution, preferably saline,and receives a single lens in situ. The blister pack is then autoclavedusing steam and pressure to terminal sterility. These blister packs arepresented to the patient in boxes of individual packs (FIGS. 4-5) or asmultiple blister strips.

The marketing objective is to present the contact lens to a patient inan aesthetically pleasing package that both satisfies the statutoryrequirements for sterility and stability, and allows the patient toremove the lens safely and easily. The packaging is used only once andis discarded after the lens is removed. This impacts the costs of thelens/package combination. In order to reduce the overall price of thelens to the patient, the cost of the packaging should be kept to anabsolute minimum. In addition, disposability of lens packagesnecessitates conformity with ecological standards.

The lens must be kept hydrated while in the package. The package must bewell sealed and should minimize water vapor transmission through theboat and laminated layer to maximize the shelf life and prevent dryingout of the lens contained therein. In use, the user removes thelaminated material from a flange formed on the boat by peeling back thecover to expose the lens immersed in a hydrating solution.

A variety of contact lens packages, particularly disposable contact lenspackages including preformed blister packs, are taught in the prior art.As exemplified in the prior art, conventional wisdom in the contact lensindustry has been to provide preformed stiff packaging which protectsthe lens from damage from applied load. Examples of typical prior artblister packs are shown in: U.S. Pat. Nos. 5,704,468; 4,392,569;5,620,087; 5,620,088; 4,691,820; 5,823,327; 5,853,085; EP PublicationNo. 1092645 A1; and EP Publication No. 0 129 388.

Flexible retort packages are also known, however, not for use withcontact lenses. U.S. Pat. No. 4,769,261 discloses a seal layer for usein large institutional sized retort pouches comprising an ABA filmstructure, wherein the A layers are each composed of a blend of a minoramount of an elastomer and a major amount of a polyolefin and the Blayer is composed of a blend of a major amount of an elastomer and aminor amount of polyolefin. Retort pouches made with the ABA filmstructure as the seal layer exhibit improved impact strength. There isno teaching in the '261 patent to use a retort package for housing acontact lens.

There is a long felt need in the disposable contact lens industry toprovide an economic, space-efficient, and convenient, disposable contactlens package without compromise to durability, sterility and utility ofthe lens.

SUMMARY

The present specification provides an economical package withoutcompromise to statutory and medical requirements of contact lenspackages.

The single-use package, in the embodiments described below, offers anumber of advantages over the prior art blister pack concept. First, thesingle-use package is smaller and slimmer which lends itself todisposability and is ideal for traveling. Additionally, the number ofpackages in a secondary container may be increased, yet storage spacefor that secondary package, may be reduced.

The single-use package may be composed of foil sheets which stabilizelight exposure and prevent oxygen transmission. Further, there is no airin the package, thus non-ballasted autoclaving is not required. Theabsence of air in the package contributes to lens stability in thepackage. Thus, the shelf-life of a contact lens in a single-use packagemay be extended. Overall, the single-use package is a more convenientand cost effective form of packaging.

Conventional contact lens packages are typically stiff and preformedwith a profiled recess to house the lens therein. The preformed recessin the known packages is intended to ensure that the lens shape ismaintained and is not deformed by the package. According to oneexemplary embodiment, a contact lens package disclosed herein does notmaintain the lens in an equilibrated position, but instead holds thelens in a flattened or compressed state.

According to another exemplary embodiment, the internal depth of acontact lens package may be less than the overall natural sagittal depthof the contact lens contained therein. Further, the single-use packagemay be flexible and not preformed, and may contribute to adjustments tothe shape of the lens in the package.

Additionally, exemplary contact lens packaging disclosed herein may varyin stiffness. More particularly, stiffness of the contact lens packagewas previously thought essential to protect the lens. However, if wallstiffness is abandoned as an essential packaging criterion, alternativecontact lens packages with significant space economy may becontemplated.

In one embodiment, a contact lens package includes a package with acontact lens therein, wherein the package has an internal depth which isless than an overall sagittal depth of the contact lens when the contactlens is in its equilibrated form.

In another exemplary embodiment, a contact lens package includes ablister package with a molded base, a cover and a contact lens therein,and the overall depth of the blister package is less than the naturalsagittal depth of the contact lens therein.

In an additional exemplary embodiment, a method of removing a contactlens from a contact lens package includes the steps of: placing apackage with a spring disc and a contact lens on an index finger;pushing the index finger through a center of the spring disc such thatthe contact lens rests on the tip of the index finger; and placing thecontact lens that rests on the index finger into an eye.

In yet another exemplary embodiment, a contact lens package is removablyadhered to a card.

An alternate embodiment provides a single use package for retaining acontact lens, with at least one barrier material defining an internalspace for holding a contact lens; a medium in the space for maintaininglens hydration; and means to enable release of the lens from said space;where at least one barrier layer is formed from a homogenous, pliablematerial.

In an additional embodiment, a single-use package capable of holding acontact lens is provided. The package has two sheets of material; and asupport member between the two sheets of material. The two sheets ofmaterial are sealed and the lens is confined in the package such that itis always maintained in the same orientation inside the package.

Also contemplated is a carton containing at least 90 single-use packageseach with a contact lens therein, where each of the packages has aninternal depth which is less than the overall sagittal depth of each ofthe contact lenses within the package.

In another exemplary embodiment, the a contact lens package with acontact lens therein, is configured such that when the package isopened, the lens is always oriented in the same position as when it wasplaced into the package.

In yet another exemplary embodiment, the a contact lens packagecontainer having a plurality of contact lenses therein is disclosed. Thecontact lens packages are dispensed such that as one contact lenspackage is removed, a next contact lens package to be dispensed isautomatically moved into a position to be removed.

In another exemplary embodiment, a single-use package with a contactlens therein is provided. The package has an internal depth that is lessthan an overall sagittal depth of the contact lens in its equilibratedform, and the package comprises two sheets of material sealed together,and at least one of the sheets has printing thereon; and at least onecorner that is not sealed so as to serve as an easy-open corner; whereinthe contact lens therein is held in a flattened state while the packageis sealed and returns to its natural state when the package is opened;and wherein the printing is selected from the group consisting ofinstructions for use and prescription information; and wherein at leastone of the sheets of material is embossed to prevent the lens fromsticking to the sheet, thus ensuring that the lens is presented in apredictable orientation when the package is opened.

Another embodiment is a single-use package with a contact lens therein.The package comprises two sheets of material sealed together; a springdisc between the sheets; and an amount of hydration medium; wherein thelens in maintained in a flattened state while the package is sealed.

Also contemplated is a method of dispensing a single-use contact lenspackage from a group of packages, the method comprising: providing adispensing container having a plurality of contact lens packagestherein; and removing at least one contact lens package from thedispenser.

Also provided is a method for opening a single-use contact lens packagehaving an internal depth that is less than the overall sagittal depth ofan equilibrated contact lens therein, the method comprising separating afirst barrier layer from a second barrier layer.

In another embodiment, a package capable of holding a contact lenstherein is disclosed. The package has at least one barrier layer ofpliable packaging material forming at least first and second opposingsurfaces which define an internal package space in which the contactlens is retained; a hydration medium in the space; and means forenabling release of the contact lens from the package; wherein the atleast one barrier layer of material is flat and is flexible.

In an alternate embodiment, a set of retort-type single-use packages forholding contact lenses therein is provided. The packages each comprise:at least one layer of pliable package material forming at least firstand second opposing surfaces which define an internal package space inwhich the contact lens is retained; a medium in the space formaintaining lens hydration; and means for enabling release of thecontact lens from the package; wherein the package material is capableof assuming a generally planar configuration; and wherein the set isformed by joining at least two the packages end to end so that a singlepackage may be torn away from an adjacent package via a frangibleconnection between the packages.

In another embodiment, a retort-type single-use package comprising aninternal space for holding a contact lens and a medium for maintaininglens hydration therein is provided.

Also contemplated is a secondary package for a plurality of contact lenspackages comprising a container, where the contact lens packagescontained therein have an internal depth that is less than the naturalsagittal depth of the contact lens therein; and wherein the container isa shape selected from the group consisting of a circle, rectangle,square, triangle, oval and symmetrical, asymmetrical and roundedvariations thereof.

In another embodiment, a contact lens travel pack includes a containerwith a lid and a base, a plurality of contact lenses packages and ahandle.

An additional embodiment provides a storage case for a plurality ofcontact lenses comprising a cover, a container for a plurality ofcontact lenses wherein the container comprises a lift-out insert.

Also contemplated is a dispensing case for a plurality of contact lensescomprising a cylindrical container wherein each of the two ends of thecontainer open to dispense the contact lenses.

An alternate embodiment is a storage stand for a plurality of contactlens packages comprising a base and a wall extending from the base,wherein the wall comprises a means for the lenses to be attachedthereto.

In another embodiment, a storage means for a plurality of contact lenseshas a plurality of contact lens holder sheets with a narrow open slot; aplurality of contact lenses attached to the holder sheets; at least onecontainer comprising a base with a narrow open guide and lid with anarrow open slot; and a stand comprising a base and a central extension.The holder sheets are stored within the container and the containerslides onto the base.

In another embodiment, a contact lens delivery package comprising analuminum coated envelope, a plurality of contact lens packages, andnitrogen gas, wherein the envelope is filled with the nitrogen gas priorto sealing.

An additional embodiment provides a package for retaining a contact lenstherein, the package comprising at least one package wall defining aninternal space for holding the contact lens; a medium in the space formaintaining lens hydration; means to enable release of the lens fromsaid space; wherein the at least one wall is formed from a homogenous ormulti-layer, pliable material.

In another embodiment, a kit of jointed single use pliable retort-typesingle use packages for each holding a contact lens is provided. Eachsingle-use package is connected to at least one adjacent package.

A method of producing a disposable contact lens package is alsodisclosed herein. The method comprises the steps of taking a singlesheet of pliable material; placing the contact lens on a surface of thesheet; dosing the surface of the material with a hydration maintenancemedium; folding the material back on itself to define a space in whichthe contact lens is held; and sealing the envelope so that the contactlens is held in a sealed environment.

Another embodiment provides a method of making a single-use package witha contact lens therein, the method comprising the following: placing aspring disc over the contact lens; dosing the spring disc and contactlens with a minimum amount of hydration medium; placing one sheet ofmaterial on top of the spring disc and lens and placing one sheet ofmaterial on the bottom of the spring disc and contact lens; and sealingthe top and bottom sheet of material.

In another embodiment, a method of making a single-use package with acontact lens therein is disclosed, wherein the package has a depth whichis less than the overall sagittal depth of the contact lens, the methodcomprising the steps of placing the lens and a minimum amount ofhydration medium between two sheets; and sealing the sheets togethersterilizing the envelope and contents; allowing access to said lens bysplitting, peeling or dividing said package along at least one edge.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawing illustrates various embodiments of the presentexemplary system and method and is a part of the specification. Theillustrated embodiments are merely examples of the present system andmethod and do not limit the scope thereof.

FIG. 1 is a plan view of a typical prior art disposable blister contactlens package.

FIG. 2 is a side elevation of the package of FIG. 1 with the lid peeledaway to release the contact lens therein.

FIG. 3 is a perspective view of the partially opened package of FIG. 2.

FIG. 4 is a side elevation view showing a stacking arrangement for twoidentical prior art contact lens packages according to one embodiment.

FIG. 5 is a perspective view showing a plurality of blister packsstacked as in FIG. 4 and contained in a carton.

FIG. 6 is a perspective view of a contact lens package opened to showembossing on the bottom sheet which has a convex indentation, accordingto one exemplary embodiment.

FIG. 7 is a perspective view of a second embodiment of a contact lenspackage like the embodiment of FIG. 6, but showing embossing on the topsheet which has a concave indentation, according to one exemplaryembodiment.

FIG. 8 is a cross-sectional view of the single-use package of FIG. 6.

FIG. 9 is a cross-sectional view of the single-use package of FIG. 7.

FIG. 10 is an example of embossing that can be used in the packages ofFIGS. 6-9, in an abstract pattern.

FIG. 11 is an example of embossing that can be used in the packages ofFIGS. 6-9, in a grid pattern.

FIG. 12 is an example of embossing that can be used in the packages ofFIGS. 6-9, with a logo.

FIG. 13 is a perspective view of a single-use package made from twodissimilar, transparent materials and illustrating a method of openingthe package having a depression which contains the contact lens.

FIG. 14 is a perspective view of a single-use package made from twosimilar, opaque materials and illustrating a method of opening thepackage having a depression which contains the contact lens.

FIG. 15 is a perspective view of a partially opened single-use packageconstructed with a support member, according to one exemplaryembodiment.

FIG. 16 is an exploded side view of the single-use package of FIG. 15.

FIG. 17 is an exploded perspective view of the single-use package ofFIG. 15.

FIG. 18 is an exploded perspective view of an alternative embodiment ofthe single-use package of FIG. 15 with a netting.

FIG. 19 is a plan view of the single-use package of FIG. 15 showing itstear drop shape.

FIG. 20 is a plan view of a single-use package like that of FIG. 15 in afigure-eight shape.

FIG. 21 is a plan view of a single-use package like that of FIG. 15 inan asymmetrical tear drop shape.

FIG. 22 is a plan view of a single-use package with a first space for acontact lens having a foil covering and a second space for hydrationmedium with a cap, according to one exemplary embodiment.

FIG. 23 is a plan view of the single-use package of FIG. 22 without thecover that encloses the lens.

FIG. 24 is a plan view of a tear drop shaped single-use package with afirst space for a contact lens having a foil covering and a second spacefor hydration medium with a cap.

FIG. 25 is a plan view of the single-use package of FIG. 24 without thecover that encloses the lens.

FIG. 26 is a side elevation view of the single-use package of FIG. 22with the cover intact.

FIG. 27 is a side elevation view of the single-use package of FIG. 22with the cover partially peeled off.

FIG. 28 is a perspective view of the single-use package of FIG. 22showing the cover being peeled off.

FIG. 29 is a plan view of another embodiment of a single-use packagewith a first space for a contact lens having a cover and a second spacefor hydration medium that has a channel 36 to release hydration mediumonce separated from the single-use package.

FIG. 30 is a plan view of the single-use package of FIG. 29 with thecover removed.

FIG. 31 is a perspective view of the single-use package of FIG. 29showing the cover being partially removed.

FIG. 32 is a side elevation view of the single-use package of FIG. 29.

FIG. 33 is a side elevation view of the single-use package of FIG. 29with the cover partially peeled off.

FIG. 34 is a perspective view of the single-use package of FIG. 30showing the first and second space of the single-use package beingseparated to release the hydration medium.

FIG. 35 is a plan view of another embodiment of a single-use packagewith a first space for a contact lens and a second space for hydrationmedium, both of which have foil covers.

FIG. 36 is a plan view of the single-use package of FIG. 35 without thecover that encloses the lens.

FIG. 37 is a side elevation view of the single-use package of FIG. 35with the cover peeled away from the first space.

FIG. 38 is a side elevation view of the single-use package of FIG. 35with the cover removed from both the first and second spaces.

FIG. 39 is a side elevation view of the single-use package of FIG. 35with the cover starting to be peeled away from the second space.

FIG. 40 is a perspective view of the single-use package of FIG. 35showing the cover being peeled away from either the first or secondspace.

FIG. 41 is a plan view of two single-use packages, each having a firstand second space, and connected by a frangible joint.

FIG. 42 is a plan view of one of the single-use packages of FIG. 41without the covering.

FIG. 43 is a perspective view of one of the single-use packages of FIG.42 showing the cover being peeled away from the first space containing acontact lens.

FIG. 44 is a side-view of the single-use package of FIG. 42 with acontact lens therein with a cover that is intact.

FIG. 45 is a side view of the single-use package of FIG. 42 with thecover peeled away and the contact lens in its equilibrated state.

FIG. 46 is a side view of a prior art blister pack with a contact lenstherein that is folded.

FIG. 47 is a side view of a prior art blister pack with a contact lenstherein that is stuck to the side.

FIG. 48 is a side view of a prior art blister pack with a contact lenstherein that is inverted.

FIG. 49A is an exploded perspective view of a sachet type single-usepackage.

FIG. 49B is a cross-sectional view of the single-use package of FIG.49A.

FIG. 50A is an exploded perspective view of a polypropylene and foiltype single-use package.

FIG. 50B is a cross-sectional view of the single-use package of FIG.50A.

FIG. 51A is an exploded perspective view of an all polypropylene typesingle-use package.

FIG. 51B is a cross-sectional view of the single-use package of FIG.51A.

FIG. 52 is a side view of another embodiment of the single-use packageshowing the internal depth of the single-use package.

FIG. 53 is a plan view of a single-use package with an island-likeprotuberance upon which the contact lens rests.

FIG. 54 is a cross-sectional view of the single-use package of FIG. 53taken along line 54-54 showing the contact lens resting on theisland-like protuberance.

FIG. 55 is another cross-sectional view of the single-use package ofFIG. 53 taken along line 55-55 showing the contact lens resting on theisland like protuberance.

FIG. 56 is a plan view of a tear shaped polypropylene support memberwith a cut out in the handle.

FIG. 57 is a cross-sectional view of a single-use package with thesupport member of FIG. 56 that is opaque.

FIG. 58 is a cross-sectional view similar to that of FIG. 57 but withthe cover peeled back.

FIG. 59 is a plan view of the front of a single-use package containingthe support member of FIG. 56.

FIG. 60 is a plan view of the back of a single-use package containingthe support member of FIG. 56.

FIG. 61 is a plan view of one embodiment of a polypropylene spring discfor use in a single-use package.

FIG. 62 is a plan view of a second embodiment of a polypropylene springdisc for use in a single-use package.

FIG. 63 is a plan view showing the inside of a single-use packagecontaining a third embodiment of a polypropylene spring disc and contactlens.

FIG. 64 is a cross-sectional view of the single-use package of FIG. 63showing a polypropylene spring disc and a contact lens in a flattenedstate.

FIG. 65 is a plan view of the front of a single-use package with reliefswithin the foil on either side of the single-use package for easyopening.

FIG. 66 is a plan view of the back view of a single-use package of FIG.65.

FIG. 67 is a cross-sectional view of a single-use package of FIG. 63showing a contact lens and polypropylene spring disc inside a single-usepackage, in a flattened configuration.

FIG. 68 is a cross-sectional view of the single-use package of FIG. 63with the cover beginning to be peeled back and the spring disc andcontact lens in an equilibrated state.

FIG. 69 is an exploded perspective view illustrating the construction ofa single-use package containing a fourth embodiment of a spring disc.

FIG. 7OA is a plan view of a fifth embodiment of a spring disc.

FIG. 70B is a side view of the embodiment of FIG. 70A showing the springdisc and contact lens in a flattened state.

FIG. 70C is a side view of the embodiment of FIG. 70A showing the springdisc and contact lens in an equilibrated state.

FIG. 71 is a plan view of a sixth embodiment of a spring disc.

FIG. 72 is a plan view of a seventh embodiment of a spring disc.

FIG. 73 is a plan view of an eighth embodiment of a spring disc.

FIG. 74 is a plan view of a ninth embodiment of a spring disc.

FIG. 75 is a plan view of a tenth embodiment of a spring disc.

FIG. 76 is a plan view of an eleventh embodiment of a spring disc.

FIG. 77 is a plan view of a twelfth embodiment of a spring disc.

FIG. 78 is a plan view of a thirteenth embodiment of a spring disc.

FIG. 79 is a plan view of a fourteenth embodiment of a spring disc.

FIG. 80 is a plan view of a fifteenth embodiment of a spring disc.

FIG. 81 is a plan view of a sixteenth embodiment of a spring disc.

FIG. 82 is a plan view of a seventeenth embodiment of a spring disc.

FIG. 83 is a plan view of an eighteenth embodiment of a spring disc.

FIG. 84 is a plan view of a nineteenth embodiment of a spring disc.

FIG. 85 is a plan view of a twentieth embodiment of a spring disc.

FIG. 86 is a perspective view of a single-use package with the springdisc of

FIG. 70A with a contact lens thereon.

FIG. 87 is a cross-sectional view of a contact lens and spring disc in aflattened state in the sealed single-use package of FIG. 90.

FIG. 88 is a cross-sectional view of a contact lens and spring disc inan equilibrated state in a single-use package of FIG. 90 with the coverremoved.

FIGS. 89A-E are perspective views of a single-use package with a springdisc and contact lens thereon with an index finger pushing through thespring disc such that the contact lens rests upon the tip of the indexfinger and the index finger extends through the opening of thesingle-use package so that the contact lens may be placed in the eye.

FIG. 90 is a plan view of a single-use package with an oval shape and atear notch.

FIG. 91 is the single-use package of FIG. 90 with the cover removed toshow the spring disc and contact lens therein.

FIG. 92 is a plan view of a single-use package with a rounded rectangleshape and a tear notch.

FIG. 93 is a plan view of a single-use package with an oval shape and apeel open hinge-type cover.

FIG. 93A is a perspective view of the single-use package of FIG. 93showing the hinge-type cover being opened.

FIG. 94 is a plan view of a single-use package with an asymmetrical tearshape and two tear notches at the narrow end.

FIG. 95 is a plan view of two of the single-use packages of FIG. 94packaged together.

FIG. 96 is a plan view of a square shaped sachet-type single-use packagewith a tear notch.

FIG. 97 is a plan view of a rounded corner square sachet-type single-usepackage with a tear-off end and cut out tabs that enhance visibility ofthe tear-off end.

FIG. 98 is a plan view of an embodiment of a sachet-type single-usepackage, half being oval shaped and half being a rounded square shapewith a half-moon tear-off end.

FIG. 99 is a plan view of a sachet-type single-use package with arounded square shape and a finger shaped tear-off end.

FIG. 100 is a plan view of two sachet-type single-use packages of FIG.99 showing the finger shaped tear-off end of one fit into the fingershaped tear-off end of the other.

FIG. 101 is a perspective view of a double curved-shape single-usepackage with the cover being peeled back to expose the lens therein.

FIG. 102 is a perspective view of a plurality of the single-use packagesof FIG. 101 stacked.

FIG. 103 is a perspective view of a molded single-use package with apull-top opening that has been peeled back to expose the inner space andcontact lens therein.

FIG. 104 is a perspective view of one embodiment of a pull-topsingle-use package with a handle detail.

FIG. 105 is a perspective view of the single-use package of FIG. 104with the top pulled back and the base bent to expose the contact lenstherein.

FIG. 106 an exploded perspective view of a single-use package with acover and base that lifts up.

FIG. 107 is a perspective view of the single-use package of FIG. 106with the cover and base lifted up.

FIG. 108 is a perspective view of an embodiment of the single-usepackage in which there is a pointed edge that breaks open the top cover.

FIG. 109 is a perspective view of the single-use package of FIG. 108with the top cover broken open.

FIG. 110 is a cross-sectional view of a single-use package with apolypropylene spring disc and a break-open edge.

FIG. 111 is a perspective view of the cross-section of the single-usepackage of FIG. 110 showing the break-open edge being broken.

FIG. 112 is a perspective view of the polypropylene spring disc used inthe embodiment of FIG. 111 and contact lens thereon.

FIG. 113 is a cross-sectional view of the single-use package of FIG. 110with a break-open edge that has been broken and has the foil coverpeeled away, allowing the polypropylene disc and contact lens tore-equilibrate.

FIG. 114 is a perspective view of a retort-type single-use packageaccording to one exemplary embodiment.

FIG. 115 is a perspective view of the retort-type single-use package ofFIG. 114 with the contact lens exposed by peeling a layer.

FIG. 116 is a plan view of a strip of retort-type single-use packages.

FIG. 117 is a plan view of the strip of retort-type single-use packagesof FIG. 116 including a hydration medium pack.

FIG. 118 is an exploded perspective view of an envelope, containing aplurality of retort-type single-use packages, packaged in a secondarypackage containing a large number of envelopes holding retort-typesingle-use packages strips according to one exemplary embodiment.

FIG. 119 is a plan view of a secondary packaging for a plurality ofsingle-use packages in which there are six stacks of five single-usepackages in separate compartments.

FIG. 120 is a cross-sectional view of the secondary packaging of FIG.119.

FIG. 121 is a perspective view of two of the secondary packages of FIG.119 stacked on top of each other, providing a 30 day supply of dailycontact lenses for each eye.

FIG. 122 is a perspective view of six of the secondary packages of FIG.119, providing a 90 day supply of daily contact lenses for each eye.

FIG. 123 is a perspective view of twelve of the secondary packages ofFIG. 119, providing a 180 day supply of daily contact lenses for eacheye.

FIG. 124 is a plan view of a travel pack with two single-use packages.

FIG. 125A is a plan view of another embodiment of secondary packaging inwhich there are three compartments each containing ten single-usepackages.

FIG. 125B is a cross-sectional view of the secondary packaging of FIG.125A.

FIG. 126 is a plan view of a transparent travel package for a pluralityof single-use packages.

FIG. 127 is a front elevation view of the travel package of FIG. 126.

FIG. 128 is a side elevation view of the travel package of FIG. 126.

FIG. 129 is a plan view of the travel package of FIG. 126 showing theinside of an open travel package holding a plurality of single-usepackages, a sliding guide for the single-use package compartment and amirror.

FIG. 130 is a side elevation view of the open travel package of FIG. 129illustrating a means of hanging the travel package on a hook.

FIG. 131 is a plan view of a travel package similar to that of FIG. 126but made of opaque material.

FIG. 132 is a plan view of an alternative embodiment of the travelpackage of FIG. 129 with a stationary guide for maintaining thesingle-use packages in compartments marked as “L” for left and “R” forright.

FIG. 133 is a side elevation view of a package capable of holding enoughsingle-use packages for 90 days of contact lens use for both right andleft eyes, and a travel package attached to the 90 day package.

FIG. 134 is a side elevation view of the 90 day package of FIG. 133without the travel package attached.

FIG. 135 is a side elevation view of the side of the 90 day package ofFIG. 133 showing that the travel pack may be slid onto the cover of the90 day package and then snapped into place.

FIG. 136 is a side elevation view of the 90 day package with the travelpack of FIG. 133 showing that the 90 day package may be used as asunglass case when all of the single-use packages have been removed.

FIG. 137 is a side elevation view of the 90 day package of FIG. 134showing that the insert containing the single-use packages may be liftedup and out of the package using the handle, once the cover to the 90 daypackage has been removed.

FIG. 137A is an exploded perspective view of a rubber stopper thatprevents the insert containing the single-use packages from slippingdown into the 90 day package.

FIG. 138 is a side elevation view of the back of a 90 day packageshowing that a tab and strip of single-use packages being lifted out ofthe 90 day package.

FIG. 138A is a plan view of a tab that indicates there are only 30contact lenses remaining in the 90 day package, as well as prescriptionand re-order information.

FIG. 138B is a plan view of a tab that indicates there are only 10lenses remaining in the 90 day package as well as prescription andre-order information.

FIG. 139 is a perspective view of the single-use package secondarypackaging container with a plurality of single-use packages therein.

FIG. 140 is a plan view of the front of a single-use package holdersheet for a plurality of single-use packages wherein the single-usepackages are arranged in a circular configuration.

FIG. 141 is a plan view of the back of the holder sheet of FIG. 140.

FIG. 142 is a plan view of the front of a single-use package holdersheet for a plurality of single-use packages wherein the single-usepackages are arranged in two parallel rows.

FIG. 143 is a plan view of the back of the holder sheet of FIG. 142.

FIG. 144 is a plan view of a blister-type single-use package of anotherexemplary embodiment.

FIG. 145 is a side elevation view of a stack of the blister-typesingle-use packages of FIG. 144.

FIG. 146 is a plan view of a secondary packaging container for aplurality of the blister-type single-use packages of FIG. 144 arrangedin a circular configuration.

FIG. 147 is an exploded perspective view of the secondary packagingcontainer of FIG. 146 also showing a lid.

FIG. 148 is a cross-sectional view of the secondary packaging containerof FIG. 147 in which there is a 30 day supply of contact lenses.

FIG. 149 is a cross-sectional view of another embodiment of a secondarypackaging container like that of FIG. 147 in which there is a 90 daysupply of contact lenses.

FIG. 150 is a plan view of another embodiment of a single-use packagewith a rounded asymmetrical triangle shape.

FIG. 151 is a plan view of a combination of six of the single-usepackages of FIG. 150 in a circular arrangement.

FIG. 152 is a plan view of a donut-shaped single-use package holdersheet.

FIG. 153 is an exploded perspective view of a plurality of the holdersheets of FIG. 152 being placed into a round box.

FIG. 154 is a perspective view of a stand for containing a plurality ofthe boxes of FIG. 153.

FIG. 155 is a perspective view of another embodiment of a secondarypackage having an eye-mask shaped and containing a plurality of roundsingle-use packages.

FIG. 156 is a plan view of two single-use packages clipped onto a sheetfor easy transport.

FIG. 157 is a plan view of another exemplary single-use package with arounded triangle shape.

FIG. 158 is a plan view of a circular secondary packaging containerwhich holds a 30 day supply of oval shaped single-use packages arrangedin a circular configuration.

FIG. 159 is a plan view of another exemplary embodiment in which arectangular secondary packaging container holds a 30 day supply ofsingle-use packages arranged in two parallel rows.

FIG. 160 is a perspective view of a secondary box for delivery of aplurality of single-use packages.

FIG. 161 is a perspective view of a stand for a 90 day supply of roundsingle-use packages.

FIG. 162 is a perspective view of a delivery package according to oneexemplary embodiment comprising an aluminum-coated envelope with aplurality of single-use packages therein.

FIG. 163 is a perspective view of a single-use package dispensing caseaccording to one exemplary embodiment.

FIG. 164 is a perspective view of the single-use package dispensing caseof FIG. 163 with one end opened and a single-use package removed.

Throughout the drawing, identical reference numbers designate similar,but not necessarily identical, elements.

DETAILED DESCRIPTION

The present exemplary systems and methods will now be describedaccording to exemplary, but non-limiting, embodiments and with referenceto the accompanying illustrations.

The term “internal depth” means the depth of a contact lens holding areawithin the contact lens package determined by subtracting the height ofthe combined opposing wall layers making up the contact lens holdingarea of the package from the total height of the contact lens holdingarea of the package when the package is lying on a flat surface.

The term “sagittal depth” means the total height of a contact lensresting in a relaxed state on a flat surface.

Referring to a contact lens in its “equilibrated state” means that thecontact lens is in a resting state unrestricted by any external forcesaffecting its shape or height.

Throughout the specification the term homogenous refers to a packagewall formed from a single layer (i.e. non-laminated layer) of the samematerial. Many of the packages described as being made from a homogenoussingle layer material may also be made from a multi-layer, laminated,material which may be formed from a combination of suitable plastics ora combination of suitable plastics and a metallic layer as describedherein.

Referring to FIGS. 1 and 2, there is shown a typical prior artdisposable blister contact lens package 1 which is formed in two parts.The package 1 comprises a blister pack member 2 which is sealed by amembrane 3 forming a lid on the package 1 and which may be peeled awayto release a contact lens 4 therein. In FIG. 3, the package of FIG. 2 isshown with the membrane 3 peeled away to expose the contact lens 4.Typically, the member 2 will be a preformed blister pack and include aprofiled recess 5 which provides a recess in which a lens may be placed.The member 2 is typically injection molded and the package is completedwith a sealing membrane 3 which mates with a flange 6 to create asterile seal. The contact lens 4 is immersed in a solution 7 which keepsthe lens hydrated until it is removed from the pack. The injectionmolded pre-form makes this an expensive package to manufacture, with theresult that the contact lens will inevitably be more expensive for theconsumer.

FIG. 4 shows a stacking arrangement for two identical prior art contactlens packages 10 and 11. It can be seen from FIG. 4 that although twopacks conveniently inter-fit, they take up a thickness greater than thethickness (or depth) of two packs. Ideally, a lens package should takeup as little space as possible considering the relatively small size ofa contact lens. Economy of storage space is a critical issue wherelenses are mass produced. The existing blister packs take up adisproportionate amount of space relative to the size of the lens,leading to increased handling and storage costs. FIG. 5 shows aplurality of like blister packs 12 stacked as in FIG. 4 and retained ina carton 13. This bulky, inconvenient, and materials-intensive form oflens packaging exists as a result of conventional wisdom which suggeststhat lenses can only be stacked in rigid containers which isolate thelens from external load.

In one exemplary embodiment of the present single-use package shown inFIGS. 6 and 8, the single-use package 18 consists of a first sheet 14and a second sheet 15 of material sealed together. In this embodiment,one of the two sheets 15 is embossed 16 and also has a convexindentation 19. The embossing 16 aids the release of the lens 4 as itprevents the lens 4 from adhering to the embossed sheet 15, as shown inFIG. 8. Therefore, it is possible to have the contact lens 4 present ina predictable orientation upon opening of the single-use package 18. Asshown in the alternate embodiment of FIGS. 7 and 9, the embossed surface16 a may alternatively be on the top sheet 14 a, which in this example,also has a concave indentation 19 a. As shown in FIG. 9, the contactlens in this example adheres to the bottom, non-embossed sheet. Theembossing 16 may take numerous forms, for example, abstract patterns,grids and logos, as shown in FIGS. 10-12. Alternatively, FIGS. 13 and 14show exemplary embodiments in which the single-use package 18 has noembossing. The sheets 14 and 15 may be opaque, transparent or colored,such as white or light green. If the sheets are colored, the color maybe displayed inwardly toward a contact lens so that the lens may beeasily seen. In addition, the sheets 14 and 15 may have printingthereon. Such printing may include, for example, symbols (such as text,diagrams, drawings), prescription, instructions, and manufactureinformation. This printing may be on the outside of the package, or morepreferably, displayed inwardly toward the contact lens (when the packageis sealed), which will increase visibility of the contact lens.

In another embodiment, shown in FIGS. 15-17 and 19, the single-usepackage 156 includes a support member 20 disposed between the sheets 14and 15. The support member 20 encircles the contact lens 4 within thesingle-use package 156. The support member 20 may be flexible rigid andmay be, for example, composed of any suitable polymers such aspolypropylene (PP), polypropylene copolymer (PPCO), polymethylpentene(TPX), polycarbonate (PC), polysulphone (PSE), polyethylene naphthalate(PEN), cyclic olefin copolymer (COC), or fluorinated ethylene propylene(FEP), or other similar material. The support member 20 does not changethe flat profile of the single-use package 156. Further, the thicknessof the support member 20 is such that the single-use package 156, whensealed, still has a depth that is less than the natural sagittal depthof the contact lens 4. The support member 20 may also serve as a handle21 (FIG. 15) to assist in moving or opening the single-use package 156.The handle area 21 may optionally have a cut out 24 that further assistsgripping the single-use package 18 as shown in FIG. 17.

In another embodiment illustrated in FIG. 18, the support member 20 ahas mesh-like netting 22. The netting 22 serves as an additional supportfor the contact lens 4 as the lens rests upon the netting 22 when in thesingle-use package 157. The netting 22 may be composed of any suitablepolymeric material such as: polypropylene (PP), polypropylene copolymer(PPCO), polymethylpentene (TPX), polycarbonate (PC), polysulphone (PSE),polyethylene naphthalate (PEN), cyclic olefin copolymer (COC), orfluorinated ethylene propylene (FEP), or other similar material.

The single-use package, with or without the support member 20, may havea variety of shapes. For example, the single-use package may be asquare, rectangle, oval, round, tear shaped, figure eight, triangle, andcombinations thereof, all of which may be symmetrical, asymmetrical,straight edged or rounded. Additional shapes are acceptable as long asthey may accommodate a soft contact lens.

In other embodiments, shown in FIGS. 22-43, the single-use package mayhave a first space 34 for a contact lens and a second space 32 forhydration medium 32. This arrangement may take on a variety ofconfigurations, some of which allow the second space for hydrationmedium to be flat, bulbous and optionally to serve as a handle. FIGS. 22and 28 illustrate that the second space 32 for hydration medium may beattached to the first space 34 for the contact lens and the two spacesare separated by a seamed connection 31 between the two sheetscomprising the single-use package 160. The connection 31 may be flexibleand frangible and thus the second space 32 may snap off as in FIG. 34,or be torn away from the first space 34 as in FIGS. 22, 28, 35 and 36.The second space 32 for the hydration medium may have a cap 30. The cap30 may be removed by pulling, twisting, or snapping off. Alternately,the second space 32 may remain connected to the first space 34 as shownin the single use package 161 of FIGS. 24-25. The first space 34 andsecond space 32 may be opened at the same time or different times. Inone example, the first space 34 for the contact lens is opened prior tothe second space for the hydration medium 32. In an alternative example,the second space 32 for the hydration medium may be opened prior to thefirst space 34 for the contact lens. The first and second space may beopened by the same or different means. The first and second space 34, 32may both be opened by peeling away a foil 26 (FIG. 28) or othercovering, or alternatively, the first space 34 may be opened by peelingaway the cover 26 and the second space 32 may be opened by removing acap 30. FIGS. 26-27 shows a first space 34 being opened by peeling awaya foil 26 or other covering, while the second space 32 remains attachedand unopened.

The cover may be heat sealed to a base, a support member or to one ofthe sheets comprising the single-use package. The heat sealing may bearound the entire perimeter or alternatively, solely around the firstspace containing the contact lens. The first and second spaces 34, 32may be separated before or after one or both of them are opened. In analternative embodiment, the second space 32 for hydration medium may beopened by separating the second space 32 from the first space 34, thusexposing an opening or channel 36 from which the hydration medium mayescape, as shown in the embodiment of the single-use package 162 of FIG.34. In another embodiment, both the first and second space may be openedby peeling a cover 26 the single-use package 163 as shown in FIG. 40.FIGS. 37-39 show that in this embodiment, the two spaces 32 and 34 maybe opened by lifting a cover 26 from either end, and may be opened atthe same time or only one space may be opened while the other remainssealed.

The hydration medium may be any solution suitable for use with contactlenses. For example, the hydration medium may be re-wetting solution,cleansing solution or any other maintenance solution. An example of asuitable hydration medium is saline solution.

In another embodiment, as shown in FIGS. 41 and 116-117, one single-usepackage 164 and 182 may be connected to another identical single-usepackage 164 and 182. The connected single-use packages may form stripsof single-use packages 41. The number of single-use packages 164connected may be between 1 and 90, or alternatively, between 90 and 180packages or more. The strips of single-use packages 41 may be rolled upor folded in zigzag fashion. The single-use packages 164 and 118,connected to form strips 41, may each have only a first space 34 for acontact lens or alternatively may have a second space for hydrationmedium 32. The connection 31 or 76 between the single-use packages isflexible and frangible. Also shown, in the embodiment of FIG. 41, theconnection is a tear notch 40 to assist in opening the single usepackage 164.

The strip of single-use packages 41, or alternatively, a plurality ofindividual single-use packages, may be used in a pop-up dispenser. Inthis embodiment, a plurality of single-use packages 164 and 118 areconnected to one another via frangible connections 31, 76 (FIGS.116-117) and are dispensed one at a time such that as one single-usepackage 164 is removed, another is available in a dispensing region ofthe dispenser. Alternatively, a plurality of individual single-usepackages are contained in a dispenser in such a way that as onesingle-use package 164 is removed, it engages a second similarsingle-use package 164, thus making the second package 164 available forsubsequent removal.

The single-use package maintains the contact lens 4 therein in acompressed state and restricts the movement of the contact lens 4 whilethe package is sealed, examples of which are shown in FIGS. 44 and 67.In FIG. 44, the single-use package 164 prevents the problematic movementof the contact lens 4 that occurs in the typical prior art blister pack27. As illustrated in FIGS. 46-48, a contact lens 4 in a prior artblister pack 27 is able to invert, shift positions, stick to the side,and fold in half. However, the single-use package, of some exemplaryembodiments, maintains the contact lens 4 in the same position as whenit is first placed within the package and sealed. In addition, thecontact lens 4 is always presented in a predictable orientation when thesingle-use package is opened. This reduces the need to handle the lensprior to insertion thus reducing the risk of lens damage orcontamination of both the lens and the eye of the wearer. This alsofacilitates placement of the contact lens in the eye of the wearer.Typically, the wearer's vision will be somewhat compromised prior toinsertion of the contact lens. Therefore, it is useful to know, withoutbeing able to see, what orientation the contact lens is in when thepackage is opened.

Even though the present exemplary contact lens package maintains thecontact lens 4 therein in a flattened or compressed state, thesingle-use package itself need not necessarily be flat. The single-usepackage may take on a variety of shapes. According to one exemplaryembodiment, the the single-use package will have a slim profile and beable to be stacked and packaged compactly, regardless of the assumedshape.

As shown in FIGS. 49A-51B, there are a variety of constructions andconfigurations useful for producing a single-use package. In FIGS. 49Aand B, a sachet type single-use package 165 is composed of three layers.The two outer layers 14, 15 are usually aluminum foil and the innerlayer is polypropylene or any other suitable polymer. The typicalthickness of this type of single-use package 165 is approximately 1.0mm, however, it can be less depending upon the choice of materials anddesign. Aluminum foil and polypropylene (or any other suitable material)may also be used in a non-sachet type single-use package 166, as shownin FIGS. 50A and B, with an approximate total thickness of 1.0-2.0 mm.In this embodiment, the foil may serve as both a cover and a base forthe package. An all polypropylene single-use package 167 may also beproduced, as in FIGS. 51A and B, with an approximate total thickness of2.0-3.0 mm. These constructions may be used to produce single-usepackages with or without spring discs 46 (FIGS. 61-69), support members20, and may be any shape or color. For instance, other suitable polymersmay be used in lieu of, or in combination with, polypropylene.

FIG. 52 is another embodiment of a single-use package 188 in which theinternal depth (“ID”) of the single-use package is shown. The internaldepth in this package is determined by measuring the height of thepackage and subtracting the thickness of the cover material 47 and thethickness of the material making up the protuberance 42. In otherpackages, there may be parts of the package which are not used to holdthe contact lens. These parts of the package are disregarded whendetermining the internal depth of the contact lens holding area. Theinternal depth of some embodiments of the present exemplary single-usepackage is approximately 0.1 mm to 3.5 mm, more preferably, 0.1 mm to3.0 mm. Regardless of the dimensions, the internal depth of theexemplary contact lens package is less than the natural sagittal depthof the contact lens in its equilibrated state, according to oneexemplary embodiment. In an equilibrated state, the natural sagittaldepth of a contact lens is typically greater than 3.8 mm, and often ashigh as 5.0 mm.

As shown in FIGS. 53-55, in one embodiment of the single-use package168, there is an island-like protuberance 42 in the recess 43, uponwhich the contact lens 4 rests. The contact lens 4 is maintained in aflattened state and is immobilized upon the protuberance 42 by the cover26 of the single-use package.

In addition, there may be a textured surface on at least one side of thesingle-use package. For example, the texture may be raised bumps, orridges and may be on one or both sides of the single-use package or on ahandle. In this embodiment, there are raised features 44 on one end ofthe single-use package to allow the user to easily grip the single-usepackage 168 as well as cut outs 24 on the corners of the base tofacilitate removal of the cover sheet 26.

In another embodiment, the single-use package 156 is a tear shape with acut out 24 in the support member 20 to facilitate handling of thesingle-use package 156. FIGS. 56-60 show the tear shaped single-usepackage 156 with and without the cover 26 in both opaque and transparentvarieties. The side view illustrates that the contact lens 4 therein ismaintained in a flattened state until the cover 26 of the single-usepackage 156 is removed.

As shown in FIG. 68, a polypropylene spring disc 46 c may be added to asingle-use package 169 to assist in maintaining the contact lens 4 in aflattened state while the single-use package 4 is sealed, and thenassist the contact lens 4 in returning to its equilibrated state whenthe single-use package 169 is opened. As shown in FIGS. 61-62, and69-86, numerous embodiments of the spring disc 46 a-t are contemplated.A unifying characteristic of all of the spring discs 46 a-t is that intheir equilibrated state, the spring discs 46 a-t is not flat. Howeverthey are compressible and are able to be maintained in a flattened statewithin the sealed single-use package 169, as shown in FIGS. 63-68.Although other variations are possible, two different ways of sealingthe single-use package are shown in FIGS. 64 and 68. In FIG. 64, the twosheets 14, 15 of material are sealed together on one end and are sealedto the spring disc therein on the other end. Alternatively, in FIG. 68,the two sheets 14, 15 of material forming the single-use package aresealed together on both ends.

FIGS. 67-68 and 110-113 illustrate that in its relaxed state, the springdisc 46 c is arched. However, when placed between the two sheets 14,15of the single-use package and sealed, the spring disc 46 c, and hencethe contact lens 4 thereon, is flattened (see FIG. 67). When thesingle-use package 169 is opened, the spring disc 46 c pops up to itsarched state and the contact lens 4 is presented in a ‘ready to insert’orientation, that is, the lens 4 may be pinched off, between the thumband forefinger, and inserted into the eye of the wearer (see FIG. 68). Aperspective view of a contact lens 4 resting on a spring disc 46 e isprovided in FIG. 86. As shown, in an equilibrated state, the spring disc46 e has projections 51 that extend upward toward the contact lens 4 andit is the projections 51 that provide support for the central portion ofthe contact lens 4 as it rests thereon. The peripheral portion of thecontact lens rests around the base 53 of the spring disc 46 e.

FIG. 69 illustrates the assembly of a single-use package 170 thatincludes a spring disc 46 d. In this embodiment, the spring disc 46 d isplaced on a molded polypropylene sheet which forms a base 50 of thesingle-use package 170. The contact lens 4 rests with its concave sideupon the spring disc 46 d and the single-use package 170 is sealed withan aluminum foil cover 26.

Preferably, the concave side of the contact lens 4 rests upon the springdisc 46 d. However, in another embodiment shown in FIGS. 87-88, theconvex side of the contact lens 4 rests upon the spring disc 46 e. Inthis embodiment, the sealed single-use package 191 holds the lens 4 andspring disc 46 e in a flattened state and when opened, both return totheir equilibrated form.

Another embodiment is presented in FIGS. 89A-E, in which a method ofinsertion made possible by using a spring disc 46 e is illustrated. Asemi-soft polypropylene spring disc 46 e is used to position the contactlens 4 in an orientation that is ready for insertion into the eye of awearer. As shown, the spring disc 46 e is placed upon the tip of anindex finger. The finger is then pushed through the center of the springdisc 46 e such that it makes contact with the convex side of the contactlens 4. The finger continues to proceed through the center of the springdisc 46 e until the spring disc 46 e drops to the base of the finger andthe contact lens 4 rests on the tip of the index finger. The contactlens 4 is then in a position to be easily inserted into the eye of thewearer. Thus, the contact lens 4 is inserted with a minimum of handling,reducing the risk of contamination to the contact lens 4 and the eye.

In another embodiment, a method of making a single-use contact lenspackage is provided. In this method, a spring disc 46 is placed on topof a contact lens 4. The spring disc 46 and contact lens 4 are thendosed with a minimum amount of hydration medium and subsequently onesheet 14 of material is placed above and one sheet 15 of material isplaced below the spring disc 46 and contact lens 4. The sheets 14, 15 ofmaterial are then sealed. In an alternative method, the spring disc 46and contact lens 4 are inverted prior to dosing with the hydrationmedium such that the hydration medium contacts the lens 4 prior to thespring disc 46. When the sealed single-use package is, opened, thespring disc 46 pops up as does the contact lens 4 thereon. Theequilibrated contact lens 4, however, will be above the level of theequilibrated spring disc 46.

One exemplary embodiment of the single-use package includes a hermeticseal, typically toward the perimeter of the package. If the package isindented, such as in FIGS. 6 and 7, the pliability of the two sheets maydiffer, and the strength of this seal may be made to vary around theperimeter, so as to make the package open in a manner that makes thelens the most easily removed as possible. In addition, packages thatinclude a spring disc may include internal seals so that the packagewill open in a predetermined fashion, thus always presenting the contactlens in a consistent orientation. For example, the single use package169 of FIG. 68 will have a seal around the perimeter. In addition, theedges of the disc 46 c will preferably be adhered to the second sheet 15with a seal that is more secure than a seal between the edges of thedisc 46 c and the first sheet 14. Then as the sheets 14 and 15 aregrasped and pulled apart, the hermetic perimeter seal will first beopened, and then the first sheet 14 will come off of the disc 46 c,leaving the disc 46 c adhered to the second sheet 15. The center of thespring portion of the disc will then always pop-up with the lens 4 ontop of it as the package is opened. (Of course this presumes that theorientation of the lens and the spring direction of the disc areconsistent from one package to the next when the package is assembled.)The shape of the hermetic seal may include point directed toward thepart of the package where the user will first spread the first andsecond sheets apart, so that the line of action of opening the sheetswill encounter this point first, and all of the opening force will bedirected to opening the hermetic seal at this point. The composition ofthe inside layers of the sheets and the disc will preferably be chosenso that they can be welded together with heat seals as is commonlyknown. The disc may be formed with an uneven surface to affect the waythe seal is formed and the strength thereof, and then be oriented withinthe package so that the first sheet 14 will more readily separate fromthe side of the disc toward the part of the package that will openfirst, and be more tightly bonded to the sheet 14 on the back part ofthe disc. This will make it easy to open the package to a good stoppingpoint where the lens is exposed for removal from the package.

Single-use packages, with and without spring discs, may take a varietyof shapes. FIG. 90 shows an oval shaped single-use package 171 with anotch 40 to aid the user in tearing the end of the cover 26 from thesingle-use package 171 to release the contact lens 4 therein. FIG. 91 isthe single-use package 171 of FIG. 90 with the cover 26 removed, thusallowing the spring disc 46 e and contact lens 4 to be seen. A roundedrectangle variation with a tear notch 40 is seen in FIG. 92.

An oval single-use package 192 with a flap-type cover 26 is shown inFIGS. 93 and 93A. The cover 26 in this embodiment is sealed around theperiphery such that it may be peeled back but not completely removed.Instead it is peeled back far enough to expose the contact lens 4 andremains connected to the single-use package 192 at a hinged area 52.Thus, once the seal is broken, the cover 26 swings back like a door toallow access to the contents of the single-use package 192.

An asymmetrical teardrop shaped single-use package 173 is seen in FIGS.94-95. In this embodiment, there are two tear notches 40 that allow theuser to tear open the single-use package, at the narrow end, to exposethe contact lens 4 therein. This shape allows two single-use packages173 to be inter-fit and stored compactly, on a disc 54, making it anideal option for a traveling consumer.

A sachet type single-use package is seen in FIGS. 96-100. In FIG. 96, atypical square shaped single-use package 169 with a tear notch 40 isseen. A rounded square with an enhanced tear-tab 53 is shown in FIG. 97.In this embodiment, the tear-tab 53 is made more visible by two centralareas 55 where foil has been cut away between the tear-tab 53 and thebody of the single-use package 193. A variation is seen in FIG. 98 wherethere are notches 40 extending from the peripheral edge to the center toenhance the visibility of the tear-tab 53.

FIG. 99 shows a rounded square shaped single-use package 175 with afinger-like tear tab 53 on one end. This tear tab 53 serves as a meansof tearing open the single-use package 175 as well as a means ofconnecting two like single-use packages 175 as seen in FIG. 100. Thefinger-like tear tabs 53 of two single-use packages inter-fit andtherefore hold the two single-use packages 175 together.

In another exemplary embodiment, a double-curve shaped single-usepackage 176 is provided (see FIG. 101). In this embodiment, a top sheet14, such as aluminum foil, may be welded to a bottom polypropylene sheet15 without wrinkling. The top sheet 14 may be pulled back to expose thecontact lens 4 therein. The double-curve shape allows a plurality ofsingle-use packages 176 to be stacked compactly as shown in FIG. 102.

In particular, as illustrated FIGS. 101 and 102, when a contact lens 4is packaged between a first curved packaging surface and a second curvedpackage surface, the resulting profile allows for compact stacking of aplurality of the packages. According to one exemplary embodiment,illustrated in FIGS. 101 and 102, the bottom curved surface, such as thepolypropylene sheet 15, of the package profile may be matingly engagedwith a curved top sheet 14 of an adjacent package having a similarprofile. By repeating the mating engagement of similarly curved topsheets 14 and bottom sheets, the packages may be compactly stacked asshown in FIG. 102.

While the compact stacking of a plurality of packages having a first anda second curved surface is illustrated in FIGS. 101 and 102 in thecontext of a package containing a compressed contact lens 4, the samestacking method may be applied to a contact lens package that tracks theprofile of a contact lens 4 without compressing the contact lenstherein. According to this exemplary embodiment, a contact lens packagehaving an internal depth less than a sagittal depth of the contact lens4 contained therein may track the profile of the contact lens, similarto the exemplary embodiments illustrated in FIGS. 8 and 9. Asillustrated, the resulting packages have a concave surface and a convexsurface. According to this exemplary embodiment, the concave bottomsurface of a first package may be matingly engaged with a convex uppersurface of a second package. Again, this stacking method may becontinued to form a compact stack of contact lens packages.

Referring to FIG. 103, the single-use package 177 has a moldedpolypropylene base 50 and transparent polypropylene pull-top cover 58.In this embodiment, the pull-top cover 58 is pulled back beginning atone corner where there is a portion of the pull-top cover 58 that is notadhered to the base 50, and is easily grasped. As the pull-top cover 58is removed, the contact lens 4 therein is exposed.

A variation of the pull-top cover 58 of FIG. 103 is shown in FIGS.104-105. In this embodiment, there is a raised handle 56 to aid inremoval of the pull-top cover 58. As shown, once the pull-top cover 58is pulled back, the base 50 is bent to allow access to the contact lens4. Although the handle 56 is provided for ease of opening, for userswith weak fingers, such as the elderly, it is possible to use a key tip,or some other device, to help grip the handle 56 and thus more easilyopen the single-use package 178.

In another exemplary embodiment, a portion of the base folds 50 backwith the cover 26. Referring to FIGS. 106-107, an elongated semi-circleshaped single-use package 79 is shown with a contact lens 4 and analuminum cover sheet 26. The base 50 is an inner elongated semi-circlesection that does not contact the peripheral section 251 except at thestraight edge 255. To open this single-use package 179, both the outerperipheral section 251 and the aluminum cover 26 are peeled back toallow easy removal of the contact lens 4 therein.

In a variation of the single-use package 180 of FIG. 108-109, there is apointed edge 62 on the inner base section 50 that facilitates removal ofthe cover sheet 26. Although the single-use package 180 of thisembodiment is shaped as a rounded rectangle, the inner section of thebase 50 is in the shape of a pointed arch. Therefore, as the peripheralportion 251 is bent down slightly, the point 62 of the arch of the innersection pierces the cover sheet 60 and the sheet is pulled back along apredetermined path, such as along a relief. Such reliefs 45 are providedfor easy opening and may be fancy cut, perforations, or semi-cut.

As shown in FIGS. 110-113, in one embodiment of the single-use package181 with a polypropylene spring disc 46 g, the single-use package 181has a tab 64 which snaps or breaks off of the main body of the pack viaa hinge 127 so that the single-use package 181 may be opened. Once theconnection between the tab 64 and the main body is broken, by snappingit upward, the protective covering 26 may be peeled away to expose thecontact lens 4 and polypropylene spring disc 46 g. As the restraint ofthe protective cover 26 is removed, the polypropylene spring disc 46 greverts to its equilibrated, arched state as does the contact lens 4thereon. The contact lens 4 may thus be pinched off between thumb andforefinger and inserted into an eye of the wearer. In this example, thespring disc 46 g is polypropylene; however, the spring disc 46 g may bemade from a variety of other materials known to those skilled in theart, such as any suitable polyolefin or other such approved materials.

In an additional embodiment, the single-use package 182 is a retort-typepackage. Referring to FIG. 114, there is shown a perspective view of aretort-type single-use package 182 according to one exemplaryembodiment. The retort-type single-use package 182 comprises a layered,flexible envelope for holding a contact lens 4, which may be formed fromone piece or two pieces of like or different flexible material.According to one embodiment, the retort-type single-use package 182 ismanufactured from a single piece of a flexible, laminated material whichis strong enough to protect a lens held in a space formed in thepackage, but flexible enough to withstand forces due to a variety ofapplied loads such as, but not limited to, bending, folding, twisting,rolling or crushing. The wall of the package, which is preferably ahomogenous material, does not necessarily conform to the shape of a lensbut rather the lens “floats” in the package. Such “floating” is achievedby the fluid forces within the close confines of the package whichsupport and buffer the lens from the surface of the package. There islittle or no air within the package, and as such, any internal movementis minimized.

The retort-type single-use package 182 may be formed by folding ahomogenous material back on itself and sealing the edges to form asterile envelope. Alternatively, the retort-type single-use package 182may be formed from two opposing pieces of homogenous material, inopposing relationship, that are heat sealed along the edges. Access tothe lens is gained by dividing the retort-type single-use package 182along one or more predetermined heat sealed edges.

In FIG. 114, the retort-type single-use package 182 comprises first andsecond barrier layers 14 and 15 which may be formed by folding one layeror by jointing two separate barrier layers. The barrier layers 14 and 15are heat sealed around edges 66, 68, 70, and 72. The heat sealing ofedges 66-72 provides a boundary defining an internal space 74 in which alens 4 is housed. The lens 4 is immersed in a predetermined, minimumamount of solution 48 which keeps the lens hydrated (see FIG. 115). Torelease and expose the lens, barrier layer 15 may be peeled away frombarrier layer 14. Alternatively, barrier layer 14 may be peeled awayfrom barrier layer 15. To facilitate initial release of the barrierlayers, a portion of the mating engagement between the layers is onlylightly sealed, preferably at a corner to enable separation of thebarrier layers. FIG. 115 shows the retort-type single-use package 182 ofFIG. 114 torn open to release the lens 4.

According to one embodiment, the barrier layers 14 and 15 aremulti-layer laminates comprising materials which enable compliance withstatutory requirements for lens packages. For example, a typicalretort-type single-use package 182 material may comprise a polyethyleneterepthelate (PET) layer, an aluminum layer and a polyolefin layer suchas polypropylene. A thin layer of aluminum has properties such asinherent pliability and inhibition of oxygen transmission which make ita good material as part of the barrier wall composite.

A retort-type single-use package 182 of a predetermined size may beformed from barrier layers of the same or different materials. Accordingto one embodiment, the retort-type single-use package 182 may be formedby folding a single piece of material back on itself to form the spacefor holding the lens. In another embodiment, two separate pieces of thesame or different material, in opposing engagement, are heat sealed attheir edges. According to one embodiment, the lamination profile of abarrier material may comprise an outer layer of 10.mu. PET, a 50.mu.aluminum layer, and a 50.mu. polypropylene layer.

Turning now to FIG. 116, a strip 41 of retort-type single-use packages182, 78, and 80 are held together by frangible joints 76. Theretort-type single-use package 182 may be separated one at a time bytearing off at the joints 76. Also, the strips may be folded aboutjoints 76 which contribute to efficient storage and packaging. Thus sixto eight, and possibly more lenses could potentially be stored in thesame space as two lenses using prior art blister packs 27.

In FIG. 117, the strip of retort-type single-use packages 182 of FIG.116 is shown, including a hydrating solution pack 35 attached to thepackage 182 via a frangible joint 76. The solution pack 35 may be usedby the consumer to hydrate the lens should supplementary lens hydrationbe required.

FIG. 118 shows an exploded view of a carton 84 containing a large numberof like envelopes 82 holding retort-type single-use package strips 41,according to one embodiment. Alternatively, the envelope may hold aplurality of individual retort-type single-use packages 182. It can beseen from this arrangement that a larger number of lenses may be storedper unit space compared to prior art packaging. Depending upon thetightness of the packaging, up to 10, and potentially more than 10lenses may be stored in a space which would previously have been takenby two lens packages.

The form of retort-type single-use packages 182 described wouldpreferably contain one soft contact lens each. The appropriate art workand statutory information may be printed on the external surfaces in asimilar fashion to the current packaging.

The integrity of the lens in this retort-type single-use package 182 ispreserved by a surrounding buffer of storage medium in the packet. Thestorage medium may act as a safety buffer if the lens package issubjected to rough or potentially damaging treatment. The currentblister pack offers lens barrier protection through the use of aninjection molded, preformed rigid boat. However, the conventionalblister package also includes an aluminum foil cover that bridges theopening to the blister pack. The unsupported foil offers no additionalprotection, and on the foil side, potentially less protection than aretort-type single-use package that has two flexible barrier layers thatrespond more favorably to applied loads. In fact, the aluminum surfaceof the blister packs can be more easily punctured due to its tightnessover the polypropylene boat. The retort-type single-use package isinherently soft and can deflect potential punctures by moving with thepuncturing object.

The retort-type single-use package 182 allows for a sufficient minimumamount of solution for maintenance of hydration and does not requirethat the lens swim in hydrating solution as in the prior art packages.

In the retort-type single-use package 182, which is one embodiment ofthe present contact lens package, excess hydration maintenance fluid maybe forced out during the manufacturing process, leaving a predeterminedminimum amount of solution or gel to keep the lens hydrated. Due to theoptimal sealing qualities of the retort-type single-use package 182, novapor will escape from the internal space. The flatness of the packagebarrier layers will facilitate sticking of the lens to one or other ofthe internal surfaces providing the advantage that when a layer ispeeled back to expose the lens inside, the lens will be stuck to aninner surface which ensures that the lens will not drop out duringopening.

The manufacturing of disposable lenses becomes more cost effective asthe cost of packaging the lens is reduced and the efficiency of sealingand subsequent sterilization is improved. Patients will be more likelyto consider the lens a disposable item in the present exemplarypackaging. Further, it takes up far less space and can be packaged in amore appealing fashion. This type of packaging especially suits dailydisposable lenses as the cost component of this type of packaging isattractive to both consumers and manufacturers.

A variety of secondary packaging 86 configurations are possible with thesingle-use package as illustrated in FIGS. 119-164. One advantage of thesingle-use package is that a variety of secondary packaging options areavailable. In addition, the space required to package a plurality ofsingle-use packages is far less than that of the traditional blisterpacks. For instance, in FIGS. 119-120, a package of 30 single-usepackages 187 is shown. There are five single-use packages 187 in each ofthe six compartments 90 sealed with a cover sheet 88, such as vacuumformed PET. The compartments 90 are connected by the cover sheet 88 asshown in FIG. 120. Two of such packages 86 may be combined to provide a30 day supply of contact lenses (that is, a total of 60 lenses) (FIG.121). In this embodiment, the 30 day supply is only270.times.60.times.12 mm. A 90 day supply of lenses (FIG. 122) is only270.times.180.times.12 mm and a package with a 180 day supply (FIG. 123)is 270.times.240.times.20 mm. The dimensions for the 30, 90 and 180packs may vary as in the following non-limiting examples. A 30 daysupply package may be 300.times.60.times.12 mm, or 255.times.60.times.13mm, or 250.times.60.times.13 mm, or 245.times.60.times.13 mm, or even240.times.55.times.13 mm. A 90 day supply pack may be300.times.180.times.12 mm, or 255.times.180.times.13 mm, or250.times.180.times.13 mm, or 245.times.180.times.13 mm, or even240.times.165.times.13. A 180 day supply pack may be300.times.240.times.20 mm, or 255.times.240.times.20 mm,250.times.240.times.20 mm, or 245.times.240.times.20 mm, or even240.times.220.times.20 mm.

In an alternative embodiment, shown in FIG. 124, a secondary package 124for two single-use contact lens packages is illustrated. In thisembodiment, two contact lens packages are packaged in a compactsecondary package that is roughly the size of a business card. Thisembodiment is particularly useful when traveling.

In an alternative embodiment, shown in FIGS. 125A and 125B, there is asecondary package 86 a for 30 single-use packages 187 with threecompartments 90 holding 10 single-use packages 187 each. Thecompartments 90 are held together by a cover sheet 88. The package 86 ais extremely compact, measuring 130.times.60.times.11 mm.

In one embodiment, a handbag kit or travel pack 91 is provided for aplurality of single-use packages 163, as seen in FIGS. 126-133, 135-136.The single-use packages therein may be individual single-use packages orstrips of single-use packages folded in zigzag fashion. The travel pack91 is composed of transparent or opaque (FIG. 131) material. The travelpack may be opened by pressing a release button 93 and flipping the top89 up. The travel pack may have a mirror 94 inside to provide atraveling user the ability to insert his contact lenses any place at anytime. Further, the handle 92 of the travel pack 91 provides a means forhanging the travel pack, for example, on a hook (see FIG. 130) such thatthe travel pack 91 is at eye level or stored in a safe place. Thesingle-use packages 163 are held in the travel pack 91 by a slidingguide 96 to prevent the single-use packages 163 from falling out, as inFIG. 129. In an alternate embodiment of the travel pack 91 a, thesingle-use packages 163 are held in compartments 98 as shown in FIG.132, which may optionally display left and right indicia 100.

In another embodiment, the secondary packaging provides a 90 day supplyof single-use packages 163 as in FIG. 133-135. FIGS. 133-134 show afront view of the 90 day package and FIGS. 135 and 137 provide a sideview. The 90 day package 104 holds the single-use packages 163 (eitherindividual or strips folded in zigzag fashion) in a stacked arrangementand has a cover 102 attached that may optionally hold a travel pack 91(FIG. 133) as described above. As shown in FIGS. 133 and 135, the travelpack 91 may slide onto the cover 102 of the 90 day package 104. Inaddition, when the 90 day package is emptied, the package 104 may beused as a sunglass case (see FIG. 136). The travel pack 91 may attach tothe cover 102 and thus a combination travel pack 91 and sunglass case104 is provided.

FIG. 137 illustrates a 90 day package 104 with a removable insert 108.After removal of the cover 102, the insert 108 may be lifted out of the90 day package 104 by the handle 109 provided. As shown in FIG. 137A, ananti-slip rubber stopper 110 prevents the insert 108 from sliding backinto the 90 day package when the user lets go of the handle 108, such aswhen the user is removing a single-use contact lens package 163. In theembodiment of FIG. 138, tabs 112 a-q are provided at regular intervalswithin the stack of single-use packages 163 to alert the user todiminishing supplies. For instance, a tab 112 a (138A) may indicate thatthere are only 30 contact lenses remaining in the 90 day package.Re-ordering information as well as prescription information may beincluded on the tab 112 b (FIG. 138B) to aid the user in purchasingadditional contact lenses. Alternatively, the tab 112 may indicate thatthere are only 10 lenses remaining. Although 10 and 30 lenses are usedas an example, the tabs 112 a-q may be placed at any interval that wouldbe useful to the contact lens wearer.

In another embodiment shown in FIG. 139, the secondary packaging 113 forthe single-use package 156 is a rectangular container or box with a lowprofile. The height of the container 113 need not be very high, as thesingle-use packages 156 within are slim and compactly stacked. Asassembled, the container 113 securely holds a plurality of single-usepackages 156 while taking up minimal space. Alternatively, the secondarypackaging 113 may be square, round, oval or any other shape conducive toholding a plurality of single-use packages 156.

In other embodiments shown in FIGS. 140-143, the single-use packages areaffixed to a holder sheet 114 and subsequently placed in a secondarypackaging container. A plurality of single-use packages 187 may beaffixed to a single holder sheet 114, and all of the single-use packages187 on a given holder sheet contain lenses of a single prescription. Thesingle-use packages 187 may be affixed in a circular arrangement, asseen in FIGS. 140-141. Alternatively, the single-use packages 187 may bearranged in parallel rows as in FIGS. 142-143. Optionally, artwork ofany variety may be displayed on the front 115 of the holder sheet inaddition to manufacture, prescription, regulatory, and instructionalinformation which may optionally be displayed on the back 116.

In another embodiment, the single-use package 183 is a blister-typepackage that may be stacked and housed in a circular configuration incircular secondary packaging, as shown in FIGS. 144-148. Theblister-type single-use package 183 is made from a suitable injectionmolded plastic material. Each blister-type single-use package has a slimprofile and maintains the contact lens therein in a flattened orcompressed state that is less that the sagittal depth of theequilibrated contact lens. When stacked, the blister-type single-usepackages stack compactly and take up minimal space. The stacks may thenbe housed in a circular configuration in a secondary package base 118with an open center 120 for easy access to the single-use packages. Inthis arrangement, it is easy for the user to place a finger in thecenter 120 and remove one or more single-use packages 183 from thecircular secondary packaging 118. The circular secondary packaging has abase 118 as well as a lid 122 for securely housing the single-usepackages 183 therein.

The circular secondary packaging 118 may house a 30 day supply, or a 90day supply of contact lenses. Alternatively (FIG. 149), the circularsecondary packaging 118 may house between 30 and 90 day supply ofcontact lenses or even between 90 and 180 day supply.

In another embodiment, the single-use package 184 is an asymmetricalrounded triangle with one or more tear notches 40, as shown in FIG. 150.This particular single-use package 184 may be packaged on a disc 223held by small tabs 126, in set of six or more in a circular arrangementas shown in FIG. 151.

An alternative embodiment is shown in FIGS. 152-154. The single-usepackage 185 is a rounded triangle that resembles the shape of a guitarpick. The single-use packages 185 are held in place on a round holdersheet 124 by clipping means 128. Thus, individual single-use packages185 may be easily removed from the sheet 124 by sliding the single-usepackage 185 off of the sheet 124. A plurality of single-use packageholder sheets 124 maybe placed in a box 123 that holds 10 or moresingle-use package holder sheets 124. More preferably, the box 123 willhold 20, 30 or more single-use package holder sheets 124. The box 123containing a plurality of single-use package holder sheets 124 has anarrow open guide 131 that matches up with slot 130 in the sheet 124.The lid 122 of box 123 also includes a slot 133. This open slot 130extends from the center of the box 123 to the periphery but does notextend all the way to the perimeter. The lid 122 of the box 123 has ahinged section 132 across the diameter of the box 123 and this hingedsection lifts up from the perimeter toward the center. There is alsoprovided a stand 136 (FIG. 136) upon which a plurality of the boxes 123containing single-use package holder sheets 124 may be stored. As shown,the stand 136 is a base with a central extension 134 that slides intoopen slot 130 of the single-use package holder sheets 124 and open guide131 of box 123. When one or more boxes 123 containing single-use packageholder sheets 124 is placed on the stand 136, the boxes 123 may be slidhorizontally along the length of the guide 131. Therefore, as shown, abox 123 that is beneath another like box 123 may slide out without beingremoved from the stand 136. Access to the contents of the box 123 may beeasily gained by opening the hinged section 132 of lid 122, and then thebox 123 may be replaced in its original position. Contact lenses forboth the right and left eye may be stored on the same stand 136. Forinstance, contact lenses for the left eye may be stored in the bottomboxes and contact lenses for the right eye may be stored in the topboxes. Alternatively, boxes may be stacked such that contact lenses forthe right and left eyes alternate. In one embodiment, it is preferablethat the boxes currently in use be on the top of the stack of boxesstored on the stand 136. This is because as each holder sheet 124 isemptied, the box 123 must be removed from the stand 136 so that thesheet 124 may be removed from the box 123 and access to a subsequentholder sheet 124 with a plurality of single-use packages 185 may begained. In an alternate embodiment, the open slot 130 in the holdersheet 124 may extend all the way to the perimeter of the sheet 124thereby allowing the sheet 124 to be removed from the box 123 withoutthe need to remove the box 123 from the stand 136.

FIG. 155 illustrates a plurality of round single-use packages 186 heldin a secondary package 145 that is shaped like an eye-mask. A pluralityof single-use packages may be held in each compartment 141 and 143 ofthe package 145. The single-use packages 186 of this exemplaryembodiment, have a semi-circular indentation 140. This indentation 140provides a place for the user to grasp the single-use package 186 andremove it from the secondary packaging 145. The eye-mask shaped package145 may be transparent or opaque and may display left and right indicia.

FIGS. 156-157 show another embodiment having a card 142 with twosingle-use packages 185 thereon. The single-use package 185 is fastenedby clipping means 128 onto a single-use package carrying card 142. Inthis instance, the card 142 holds two rounded triangular shapedsingle-use packages 185. However, the number of single-use packages 185as well as the shape of the single-use packages 185 may vary. Althoughthe single-use packages in this example are attached to the single-usepackage holder card via clipping means, the single-use packages may alsobe attached with other forms such as adhesive or alternatively,insertion slots into which the corners of the single-use package mayslide.

Advantageously, the card 142 with two single-use packages 185 clippedthereon may hold one left and one right daily use lens. Thus, a one daysupply of lenses may be easily and compactly transported in a purse,wallet or pocket, as the card 142 is roughly the size of a businesscard. Optionally, a plurality of two single-use package carrying cards142 may be packaged in a container for delivery to the user. Thecontainer may contain 10, 20, 30, 90 or a 180 day supply of lenses.

FIGS. 158-159 illustrate variations of the secondary package 114 of FIG.146 that are possible with the single-use package 187. A variety ofdifferently shaped single-use packages 187 may be compactly packaged ina variety of configurations with minimal space required. In FIG. 158,six single-use packages 187 are attached to a round holder sheet 248. InFIG. 159, six single-use packages 187 are attached to a rectangularholder sheet 249. Both holder sheet 248 and 249 include central openingstherein, like opening 120 in FIG. 146, to allow a user to remove one ofthe packages 187 from the holder sheet.

Referring to FIG. 160, a secondary packaging box 250 is provided for aplurality of circular single-use packages 188. The circular single-usepackages have a section of the perimeter that is folded inwardly to forman opening 146 into which a clip 147 may fit and hold the single-usepackages in place. A storage stand 144 is provided in FIG. 161 whichconsists of a base and a wall that is at approximately a right angle tothe base. The plurality of circular single-use packages may betransferred from the secondary packaging box 250 of FIG. 160 and clippedor snapped onto the stand 144 for storage of a 90 day supply of contactlenses. Single-use packages 188 may be removed from the stand 144 asneeded. As shown, in this embodiment, there are two stacks of single-usepackages 188 on the stand 144. Therefore, one stack may hold single-usepackages 188 containing a prescription contact lens for the left eye andone stack may hold packages containing contact lenses suited to theright eye. The stand may be reusable or disposable and may store greateror less than a 90 day supply of lenses.

A delivery package is shown in FIG. 162. A plurality of single-usepackages 190, in virtually any of the previously described packageembodiments, may be inserted into an envelope 148 for shipping.Preferably, the envelope 148 is a sealed aluminum-coated sac filled withnitrogen gas to act a cushion. The packages 190 may be adhered to sheetsor the packages themselves may be perforated portions of a larger sheet124.

A single-use package dispensing case is illustrated in FIGS. 163-164.The dispensing case 150 opens from both ends to dispense single-usepackages 189. For instance, one end dispenses single-use packages 189containing contact lenses for the left eye and the opposite enddispenses single-use packages 189 containing contact lenses for theright eye. The dispensing case 150 is a cylinder and the single-usepackages 189 therein are stacked on an angle such that when a cap 152 isopened, a single-use package 189 may be easily accessed by applyingpressure to the removal area 154 and sliding a single-use package 189from the dispenser 150. The caps 152 may display left and right indicia,prescription information, etc. The dispensing case 150 may be refillableor alternatively disposable.

It will be recognized by persons skilled in the art that numerousvariations and modifications may be made to the described systems andmethods as broadly described herein without departing from the overallspirit and scope thereof. For example, the materials discussed hereinare capable of autoclave sterilization. Other materials may be used whenother means of sterilization are utilized.

The preceding description has been presented only to illustrate anddescribe exemplary embodiments of the present system and method. It isnot intended to be exhaustive or to limit the system and method to anyprecise form disclosed. Many modifications and variations are possiblein light of the above teaching. It is intended that the scope of thesystem and method be defined by the following claims.

What is claimed is:
 1. A contact lens delivery package, comprising: a sealed envelope defining a volume; at least one independently sealed contact lens package containing a contact lens the independently sealed contact lens package being disposed within the sealed envelope and occupying a first portion of the volume; and a second portion of the volume being filled with an inert gas.
 2. The contact lens delivery package of claim 1, wherein the inert gas comprises nitrogen.
 3. The contact lens delivery package of claim 1, wherein the inert gas displaces air such that the shelf life of the contact lens is extended within the independently sealed contact lens package.
 4. The contact lens delivery package of claim 1, wherein the sealed envelope is coated with aluminum.
 5. The contact lens delivery package of claim 1, wherein the independently sealed contact lens package is sealed within the sealed envelope.
 6. A contact lens package assembly, comprising: a sealable contact lens package; at least one contact lens sealed within the sealable contact lens package; and a sealable envelope; wherein the sealable contact lens package is sealed within the sealable envelope, the sealable envelope including an inert gas therein; wherein the seal of the sealable contact lens package and the seal of the sealable envelope comprise different seals.
 7. The contact lens package assembly of claim 6, wherein the sealable envelope is configured to retain a plurality of primary lens packages.
 8. The contact lens package assembly, of claim 6, wherein the at least one inert gas comprises nitrogen.
 9. The contact lens package assembly of claim 6, wherein the sealable envelope comprises an aluminum layer.
 10. The contact lens delivery package of claim 6, wherein the inert gas is configured to displace air such that the shelf life of the at least one contact lens is extended within the sealable contact lens package.
 11. The contact lens delivery package of claim 10, wherein the contact lens package comprises two sheets of material sealed together.
 12. The contact lens delivery package of claim 11, further comprising a first seal surrounding the contact lens, and a second seal around a perimeter of the package, wherein the first seal is stronger than the second seal.
 13. The contact lens delivery package of claim 10, wherein the contact lens package comprises a first space containing a hydration medium and a second space containing the hydration medium, wherein the first space and the second space are separated by a seam.
 14. A method for manufacturing a contact lens package, comprising: sealing a contact lens within a contact lens package; and sealing the contact lens package within an envelope, wherein the envelope is configured to provide an inert environment for the contact lens package by sealing a volume of inert gas within the envelope with the contact lens package; wherein the sealing of the contact lens package and the sealing of the envelope comprise different sealing processes.
 15. The method of claim 14, wherein the inert gas comprises nitrogen.
 16. The method of claim 14, wherein the inert gas displaces air such that the shelf life of the contact lens is extended within the contact lens package. 